U.S. patent application number 12/632473 was filed with the patent office on 2010-06-10 for casing and method for manufacturing the same.
This patent application is currently assigned to Pegatron Corporation. Invention is credited to Chih Chieh Chou, Chia Ming Tsai.
Application Number | 20100143650 12/632473 |
Document ID | / |
Family ID | 42231403 |
Filed Date | 2010-06-10 |
United States Patent
Application |
20100143650 |
Kind Code |
A1 |
Tsai; Chia Ming ; et
al. |
June 10, 2010 |
CASING AND METHOD FOR MANUFACTURING THE SAME
Abstract
This invention discloses a casing and a method for manufacturing
the same. The casing includes a fiber-reinforced thermosetting
polymeric mat and a fiber-reinforced thermoplastic polymeric mat.
The fiber-reinforced thermosetting polymeric mat is molded to have
a predetermined shape with a curved inner surface. The
fiber-reinforced thermoplastic polymeric mat is molded on the inner
surface of the fiber-reinforced thermosetting polymeric mat and
agrees with the curved inner surface.
Inventors: |
Tsai; Chia Ming; (Taipei
City, TW) ; Chou; Chih Chieh; (Taipei City,
TW) |
Correspondence
Address: |
MORRIS MANNING MARTIN LLP
3343 PEACHTREE ROAD, NE, 1600 ATLANTA FINANCIAL CENTER
ATLANTA
GA
30326
US
|
Assignee: |
Pegatron Corporation
Taipei City
TW
|
Family ID: |
42231403 |
Appl. No.: |
12/632473 |
Filed: |
December 7, 2009 |
Current U.S.
Class: |
428/139 ;
264/101; 264/248; 264/259; 428/174 |
Current CPC
Class: |
B29C 66/712 20130101;
B32B 2457/00 20130101; B29C 70/086 20130101; B32B 15/08 20130101;
B29K 2101/12 20130101; B29C 66/72141 20130101; B29C 66/1122
20130101; B29C 66/304 20130101; B32B 3/266 20130101; B29K 2305/00
20130101; B29C 66/8322 20130101; B32B 3/02 20130101; B32B 27/20
20130101; B29C 33/14 20130101; B29C 65/18 20130101; B29L 2009/00
20130101; Y10T 428/24339 20150115; B29C 70/088 20130101; B29C
66/72321 20130101; B29C 66/73161 20130101; B32B 3/08 20130101; B29K
2101/10 20130101; B29C 70/46 20130101; B29K 2105/06 20130101; B29C
66/45 20130101; B29C 66/721 20130101; Y10T 428/24628 20150115; B29C
66/7392 20130101; B29C 66/7394 20130101; B32B 27/08 20130101; B29C
66/301 20130101; B29L 2009/003 20130101 |
Class at
Publication: |
428/139 ;
264/259; 264/248; 264/101; 428/174 |
International
Class: |
B32B 3/10 20060101
B32B003/10; B29C 43/20 20060101 B29C043/20; B29C 65/02 20060101
B29C065/02; B32B 3/00 20060101 B32B003/00 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 9, 2008 |
TW |
097147868 |
Claims
1. A method for manufacturing a casing, the method comprising the
following steps of: (a) molding a fiber-reinforced thermosetting
polymeric mat to allow the fiber-reinforced thermosetting polymeric
mat to have a predetermined shape with a curved inner surface; (b)
disposing a fiber-reinforced thermoplastic polymeric mat on the
inner surface of the fiber-reinforced thermosetting polymeric mat
to allow the fiber-reinforced thermoplastic polymeric mat to agree
with the curved inner surface; and (c) molding the fiber-reinforced
thermoplastic polymeric mat.
2. The method according to claim 1, wherein the step (c) is
performed via a hot press molding process.
3. The method according to claim 1, wherein the step (c) further
comprises the step of molding and joining a structural part to the
fiber-reinforced thermoplastic polymeric mat via a hot press
molding process.
4. The method according to claim 1, between the step (a) and the
step (b), further comprising the following step of: disposing a
buffer layer on the inner surface of the fiber-reinforced
thermosetting polymeric mat to allow the buffer layer to agree with
the curved inner surface, wherein the fiber-reinforced
thermoplastic polymeric mat is disposed on the buffer layer.
5. The method according to claim 4, wherein the buffer layer is
made of a metal material or a polymer.
6. The method according to claim 4, wherein the buffer layer has a
plurality of through holes, and in the step (c), a part of the
fiber-reinforced thermoplastic polymeric mat passes through the
through holes further to be joined to the buffer layer.
7. The method according to claim 4, wherein the buffer layer has a
plurality of through holes, and in the step (c), a part of the
fiber-reinforced thermoplastic polymeric mat passes through the
through holes further to be joined to the fiber-reinforced
thermosetting polymeric mat.
8. The method according to claim 1, wherein the fiber-reinforced
thermosetting polymeric mat is molded via a vacuum molding
process.
9. A casing comprising: a fiber-reinforced thermosetting polymeric
mat molded to have a predetermined shape with a curved inner
surface; and a fiber-reinforced thermoplastic polymeric mat molded
on the inner surface of the fiber-reinforced thermosetting
polymeric mat and agreeing with the curved inner surface.
10. The casing according to claim 9, further comprising a
structural part molded and joined to the fiber-reinforced
thermoplastic polymeric mat via a hot press molding process.
11. The casing according to claim 9, further comprising a buffer
layer disposed between the fiber-reinforced thermoplastic polymeric
mat and the fiber-reinforced thermosetting polymeric mat.
12. The casing according to claim 11, wherein the buffer layer is
made of a metal material or a polymer.
13. The casing according to claim 11, wherein the buffer layer has
a plurality of through holes, and a part of the fiber-reinforced
thermoplastic polymeric mat passes through the through holes
further to be joined to the buffer layer.
14. The casing according to claim 11, wherein the buffer layer has
a plurality of through holes, and a part of the fiber-reinforced
thermoplastic polymeric mat passes through the through holes
further to be joined to the fiber-reinforced thermosetting
polymeric mat.
15. The casing according to claim 9, wherein the opposite surface
of the inner surface is a decorative outer surface of the
casing.
16. The casing according to claim 9, wherein the fiber-reinforced
thermosetting polymeric mat is molded via a vacuum molding process.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a casing and a method for
manufacturing the same and, more particularly, to a casing
manufactured by a fiber-reinforced polymeric mat and a method for
manufacturing the same.
[0003] 2. Description of the Prior Art
[0004] To reduce weight, a plurality of polymers such as
thermosetting resin or thermoplastic resin have been widely applied
to casings of electronic devices. Further to improve strength of a
casing made of a polymer, application of fiber-reinforced
thermosetting polymers and fiber-reinforced thermoplastic polymers
has been gradually widened. As people begin to require aesthetics
of appearances of electronic devices, an outer surface of a casing
made of a fiber-reinforced polymer can provide a grain or texture
of the fabric used by the casing thus to present a decorative
effect. However, different manufacturing processes are needed by
the fiber-reinforced thermosetting polymer or the fiber-reinforced
thermoplastic polymer to manufacture a casing.
[0005] When the fiber-reinforced thermosetting polymer is used to
manufacture a casing, a vacuum molding process is generally
performed. A fiber-reinforced thermosetting polymeric mat is first
cut and then is disposed at an inner wall of a mold. Then, the mold
where the fiber-reinforced thermosetting polymeric mat is disposed
is disposed in a vacuum pan further to perform a vacuum pumping
process and to rise to a proper temperature. Finally, the mold
where the fiber-reinforced thermosetting polymeric mat is disposed
is taken away from the vacuum pan, and the casing manufactured by
processing the fiber-reinforced thermosetting polymeric mat is
separated from the mold. If a structural part needs to be assembled
at the inner wall of the casing manufactured by the
fiber-reinforced thermosetting polymeric mat, the structural part
can be assembled at the inner wall of the casing manufactured by
the fiber-reinforced thermosetting polymeric mat just in a
dispensing mode or via twin adhesive. Apparently, the join strength
of the structural part assembled at the inner wall of the casing
manufactured by the fiber-reinforced thermosetting polymeric mat is
rather weak.
[0006] When the fiber-reinforced thermoplastic polymer is used to
manufacture a casing with a structural part, a hot press molding
process is performed. A fiber-reinforced thermoplastic polymeric
mat is first cut and then is disposed at an inner wall of a lower
mold. Then, the structural part is disposed in an upper mold. Then,
the upper mold and the lower mold are closed further to perform the
hot press molding process. In the hot press molding process, the
structural part may be inserted into the fiber-reinforced
thermoplastic polymeric mat with molten surfaces further to cause
the structural part to be partly molten, thus to allow the
structural part to be joined to the inner wall of the casing
manufactured by the fiber-reinforced thermoplastic polymeric mat.
Apparently, the join strength of the structural part disposed at
the inner wall of the casing manufactured by the fiber-reinforced
thermoplastic polymeric mat is rather strong. However, in the hot
press molding process, the fiber grain of the fiber-reinforced
thermoplastic polymeric mat may be deformed due to the flow of the
molten structural part, further to deteriorate the appearance of
the formed casing thus to fail to provide a better grain and
texture.
[0007] With continuous development of the fiber-reinforced polymers
applied to the casing manufacture, the manufacturing technique
combining the advantages of the fiber-reinforced thermosetting
polymer and the fiber-reinforced thermoplastic polymer applied to
the casing manufacture and without the disadvantages thereof is
still not provided.
SUMMARY OF THE INVENTION
[0008] One objective of this invention is to provide a casing and a
method for manufacturing the same. According to the invention, the
casing combines advantages of a fiber-reinforced thermosetting
polymer and a fiber-reinforced thermoplastic polymer applied to the
casing manufacture. Thus, the casing has an outer surface with a
better grain and texture, and better join strength between the
casing and a structural part assembled at an inner wall of the
formed casing is provided.
[0009] According to one aspect of the invention, the invention
provides a casing. The casing includes a fiber-reinforced
thermosetting polymeric mat and a fiber-reinforced thermoplastic
polymeric mat. The fiber-reinforced thermosetting polymeric mat is
molded to have a predetermined shape with a curved inner surface
according to a needed appearance. The fiber-reinforced
thermoplastic polymeric mat is molded on the inner surface of the
fiber-reinforced thermosetting polymeric mat and agrees with the
curved inner surface.
[0010] According to another aspect of the invention, the invention
provides a method for manufacturing a casing. According to the
method, a fiber-reinforced thermosetting polymeric mat is first
molded to allow the fiber-reinforced thermosetting polymeric mat to
have a predetermined shape with a curved inner surface. Then, a
fiber-reinforced thermoplastic polymeric mat is disposed on the
inner surface of the fiber-reinforced thermosetting polymeric mat
to allow the fiber-reinforced thermoplastic polymeric mat to agree
with the curved inner surface. Finally, the fiber-reinforced
thermoplastic polymeric mat is molded.
[0011] These and other features, aspects, and advantages of the
present invention will become better understood with regard to the
following description, appended claims, and accompanying
drawings.
BRIEF DESCRIPTION OF THE APPENDED DRAWINGS
[0012] FIG. 1A is a schematic diagram showing a casing and a
section thereof according to one preferred embodiment of the
invention;
[0013] FIG. 1B is a schematic diagram showing a casing and a
section thereof according to another preferred embodiment of the
invention; and
[0014] FIG. 2A to FIG. 2D are sectional schematic diagrams
corresponding to a method for manufacturing a casing according to
one preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0015] This invention provides a casing and a method for
manufacturing the same. According to the invention, the casing
combines advantages of a fiber-reinforced thermosetting polymer and
a fiber-reinforced thermoplastic polymer applied to casing
manufacture and does not have disadvantages of the two materials
when they are respectively applied to the casing manufacture.
Preferred embodiments of the invention are described in detail
hereinafter. Thereby, the features, aspects, advantages, and
feasibility of mass production of products are described.
[0016] FIG. 1A is a schematic diagram showing a casing 1 and a
section thereof according to one preferred embodiment of the
invention. Please refer to FIG. 1A. According to one preferred
embodiment of the invention, the casing 1 includes a
fiber-reinforced thermosetting polymeric mat 12 and a
fiber-reinforced thermoplastic polymeric mat 16.
[0017] The fiber-reinforced thermosetting polymeric mat 12 is first
molded to have a predetermined shape. The predetermined shape has a
curved inner surface 124. The opposite surface of the curved inner
surface 124 is a decorative outer surface 122. That is, the outer
surface of the fiber-reinforced thermosetting polymeric mat 12 has
a fabric grain and texture to present an appearance vision
effect.
[0018] In one embodiment, the fiber-reinforced thermosetting
polymeric mat 12 may be molded via a vacuum molding process.
[0019] The fiber-reinforced thermoplastic polymeric mat 16 is
molded on the inner surface 124 of the fiber-reinforced
thermosetting polymeric mat 12 and agrees with the curved inner
surface 124. In one embodiment, the fiber-reinforced thermoplastic
polymeric mat 16 may be molded via a hot press molding process to
allow the fiber-reinforced thermoplastic mat 16 to be joined to the
fiber-reinforced thermosetting polymeric mat 12.
[0020] In FIG. 1A, in another embodiment, the casing 1 further
includes a structural part 18. Particularly, the structural part 18
is joined to the fiber-reinforced thermoplastic polymeric mat 16
via a hot press molding process. Further, in the hot press molding
process, the fiber-reinforced thermoplastic polymeric mat 16 and
the fiber-reinforced thermosetting polymeric mat 12 are joined
together.
[0021] To prevent a polymer of the fiber-reinforced thermoplastic
polymeric mat 16 from permeating into the fiber-reinforced
thermosetting polymeric mat 12 in the hot press molding process
further to damage appearance of the molded fiber-reinforced
thermosetting polymeric mat 12, in FIG. 1A, in another preferred
embodiment, the casing further includes a buffer layer 14. The
buffer layer 14 is disposed between the fiber-reinforced
thermoplastic polymeric mat 16 and the fiber-reinforced
thermosetting polymeric mat 12. That is, the fiber-reinforced
thermoplastic polymeric mat 16 is disposed on the buffer layer 14.
In the hot press molding process, the fiber-reinforced
thermoplastic polymeric mat 16, the buffer layer 14, and the
fiber-reinforced thermosetting polymeric mat 12 are joined
together.
[0022] However, provision of the buffer layer 14 is just one
preferred embodiment. The invention is not limited thereto. Since
the fiber-reinforced thermosetting polymeric mat 12 is first molded
via a vacuum molding process, in the succeeding process of
disposing the fiber-reinforced thermoplastic polymeric mat and
combining the fiber-reinforced thermoplastic polymeric mat with the
structural part, when the proper temperature or pressure is
controlled and the molded fiber-reinforced thermosetting polymeric
mat 12 is principally not damaged, the buffer layer 14 can be
omitted.
[0023] In one embodiment, the buffer layer 14 may be made of a
metal material or a polymer. The buffer layer 14 may allow the
casing 1 to have other physical characteristics such as protection
against electromagnetic interference.
[0024] To improve the join strength between the fiber-reinforced
thermoplastic polymeric mat 18, the buffer layer 14, and the
fiber-reinforced thermosetting polymeric mat 12, in FIG. 1B, in
another preferred embodiment, the buffer layer 14 has a plurality
of through holes 142. In the hot press molding process, a part of
the fiber-reinforced thermoplastic polymeric mat 16 passes through
the through holes 142 further to be joined to the buffer layer 14
or the fiber-reinforced thermosetting polymeric mat 12. Thereby,
the join strength of the fiber-reinforced thermoplastic polymeric
mat 16, the buffer layer 14, and the fiber-reinforced thermosetting
polymeric mat 12 is improved.
[0025] The elements in FIG. 1B having the same marks with that in
FIG. 1A are the material layers mentioned above. Therefore, they
are not described for a concise purpose.
[0026] The design of the buffer layer with holes is not necessary.
The thermosetting polymeric mat is first molded, and in the hot
press molding process, the thermoplastic plastic included by the
fiber-reinforced thermoplastic polymeric mat and a part of a
thermoplastic structural part may be melted and then solidified.
When solidified, the molten part of the structural part may be
fused to the fiber-reinforced thermoplastic polymeric mat to be
combined with the molten thermoplastic plastic. At that moment, the
molten thermoplastic plastic of the fiber-reinforced thermoplastic
polymeric mat may be combined or solidified to the inner layer of
the molded fiber-reinforced thermosetting polymeric mat. In
addition, after the fiber-reinforced polymeric mat is molded, the
inner layer thereof may present a natural rough surface of a fiber
caused by the different processes, and the rough surface can
improve the join strength between the structural part and the
thermoplastic polymeric mat.
[0027] FIG. 2A to FIG. 2D are sectional schematic diagrams
corresponding to a method for manufacturing a casing according to
one preferred embodiment of the invention. The method is described
in detail hereinafter.
[0028] According to the method, a fiber-reinforced thermosetting
polymeric mat 12 is first molded to allow the fiber-reinforced
thermosetting polymeric mat 12 to have a predetermined shape. In
one embodiment, in FIG. 2A, the fiber-reinforced thermosetting
polymeric mat 12 is first cut and then is disposed at an inner wall
of a lower mold 22. Then, the lower mold 22 where the
fiber-reinforced thermosetting polymeric mat 12 is disposed is
disposed in a vacuum pan (not shown in FIG. 2A) further to perform
a vacuum pumping process and to rise to a proper temperature.
Particularly, after the lower mold 22 where the fiber-reinforced
thermosetting polymeric mat 12 is disposed is taken away from the
vacuum pan, the casing is not separated from the lower mold 22, and
the next process is performed directly. The predetermined shape has
a curved inner surface 124. In addition, the opposite surface of
the curved inner surface 124 is a decorative outer surface 122.
[0029] Then, according to the method, a buffer layer 14 is disposed
on the inner surface 124 of the fiber-reinforced thermosetting
polymeric mat 12 to allow the buffer layer 14 to agree with the
curved inner surface 124 as shown in FIG. 2B.
[0030] Afterwards, in FIG. 2C, according to the method, a
fiber-reinforced thermoplastic polymeric mat 16 is disposed on the
buffer layer 14 to allow the fiber-reinforced thermoplastic
polymeric mat 16 to agree with the predetermined shape. If the
material is proper and the injection parameter is controlled
properly, there is no need to provide the buffer layer 14, and the
fiber-reinforced thermoplastic polymeric mat 16 may be directly
disposed on the inner surface 124 of the fiber-reinforced
thermosetting polymeric mat 12.
[0031] Finally, via a hot press molding process, the
fiber-reinforced thermoplastic polymeric mat 16 is molded.
Particularly, in the hot press molding process, the
fiber-reinforced thermosetting polymeric mat 12, the buffer layer
14, and the fiber-reinforced thermoplastic polymeric mat 16 are
joined together. Then, after the mold and the casing are separated
from each other, the casing is completed. If a structural part
needs to be assembled at the inner wall of the casing, the hot
press molding process also needs to be performed to allow the
structural part 18 to be joined to the fiber-reinforced
thermoplastic polymeric mat 16. In one embodiment, in FIG. 2D, an
upper mold 24 cooperating with the lower mold 22 is prepared. The
upper mold 24 has inserting holes, and the structural parts 18 are
inserted into the inserting holes of the upper mold 24. Then, the
upper mold 24 and the lower mold 22 are closed to perform the hot
press molding process as shown in FIG. 2D. In the hot press
process, a molten part of the structural part 18 may be fused to
the fiber-reinforced thermoplastic polymeric mat 16 and be combined
with the molten thermoplastic plastic included by the polymeric
mat, further to allow the structural part 18 to be molded on the
fiber-reinforced thermoplastic polymeric mat 16. Particularly, in
the hot press molding process, the fiber-reinforced thermoplastic
polymeric mat 16, the buffer layer 14, and the fiber-reinforced
thermosetting polymeric mat 12 are joined together. Then, after the
molds are separated from each other, the casing 1 as shown in FIG.
1A is completed.
[0032] In another preferred embodiment, the buffer layer 14 can
form a plurality of through holes 142 as shown in FIG. 1B in
advance. In the hot press molding process, a part of the
fiber-reinforced thermoplastic polymeric mat 16 may pass through
the through holes 142 to be joined to the buffer layer 14 or the
fiber-reinforced thermosetting polymeric mat 12. Thereby, the join
strength of the fiber-reinforced thermoplastic polymeric mat 16,
the buffer layer 14, and the fiber-reinforced thermosetting
polymeric mat 12 is improved.
[0033] According to the preferred embodiments of the invention, the
casing combines the advantages of the fiber-reinforced
thermosetting polymer and the fiber-reinforced thermoplastic
polymer applied to the casing manufacture and does not have the
disadvantages of the two materials when they are respectively
applied to the casing manufacture in the prior art. Further, one
lower mold can be universally used in the vacuum molding process
and the hot press molding process, which greatly improves
feasibility of the mass production of the products.
[0034] Although the present invention has been described in
considerable detail with reference to certain preferred embodiments
thereof, the disclosure is not for limiting the scope of the
invention. Persons having ordinary skill in the art may make
various modifications and changes without departing from the scope
and spirit of the invention. Therefore, the scope of the appended
claims should not be limited to the description of the preferred
embodiments described above.
* * * * *